Engineered composite systems

ABSTRACT

A system for providing improved engineered-composite materials, equipment, and manufacturing processes

CROSS-REFERENCE TO RELATED APPLICATIONS

This U.S. Continuation application claims priority to U.S.Non-Provisional patent application Ser. No. 14/207,790, which was filedon Mar. 13, 2014, entitled “ENGINEERED COMPOSITE SYSTEMS” which claimspriority to U.S. Provisional Patent Application Ser. No. 61/780,345filed Mar. 13, 2013 entitled “ENGINEERED COMPOSITE SYSTEMS”, all ofwhich is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

Related disclosures are found in U.S. Pat. No. 5,470,062, entitled“COMPOSITE MATERIAL FOR FABRICATION OF SAILS AND OTHER ARTICLES,” whichwas issued on Nov. 28, 1995; and U.S. Pat. No. 5,333,568, entitled“MATERIAL FOR THE FABRICATION OF SAILS” which was issued on Aug. 2,1994; and U.S. patent application Ser. No. 13/168,912, filed Jun. 24,2011 entitled “WATERPROOF BREATHABLE COMPOSITE MATERIALS FOR FABRICATIONOF FLEXIBLE MEMBRANES AND OTHER ARTICLES,”; and U.S. patent applicationSer. No. 13/197,741, filed Aug. 3, 2011 entitled “SYSTEM AND METHOD FORTHE TRANSFER OF COLOR AND OTHER PHYSICAL PROPERTIES TO LAMINATECOMPOSITE MATERIALS AND OTHER ARTICLES”, the contents of all of whichare hereby incorporated by reference for any purpose in their entirety.

This invention relates to improved flexible composite systems. Moreparticularly, this invention relates to a system for quickly andeconomically producing high-quality engineered-composite materialsexhibiting enhanced “stretch” properties, or modulus attained, orrebound ability. Such composites would be of benefit within manytechnical fields.

Further, this invention relates to providing improvedmonofilament-related products, methods, and equipment. Moreparticularly, this invention relates to providing systems for design andmanufacture of products using the technologies and useful arts hereintaught and embodied. Even more particularly, this invention providesimprovements in efficiently controlling properties of fabric-relatedproducts, including but not limited to: weight, rigidity, penetrability,waterproof-ability, breathability, color, mold-ability, cost,customizability, flexibility, package-ability, etc., including desiredcombinations of such properties.

In the past, there has been difficulty in achieving desired combinationsof such properties, especially with regard to fabric-related productslike clothing and shoes, camping and hiking goods, comfortable armor,protective inflatables, etc.

OBJECTS AND FEATURES OF THE INVENTION

A primary object and feature of the present invention is to provide asystem overcoming the above-mentioned problem.

Another primary object and feature of the present invention is toprovide a system to fine-tune, at desired places on a product,directional control of rigidity/flexibility/elasticity properties.

Yet another primary object and feature of the present invention is toprovide products combining extreme light weight with extreme strength.

A further primary object and feature of the present invention is toprovide such a system that is efficient, inexpensive, and handy. Otherobjects and features of this invention will become apparent withreference to the following descriptions.

SUMMARY OF THE INVENTION

In accordance with a preferred embodiment hereof, this inventionprovides a laminate including reinforcing elements therein, suchreinforcing elements including at least one unidirectional tape havingmonofilaments therein, all of such monofilaments lying in apredetermined direction within the tape, wherein such monofilaments havediameters less than 20 microns and wherein spacing between individualmonofilaments within an adjoining strengthening group of monofilamentsis within a gap distance in the range between non-abutting monofilamentsup to nine times the monofilament major diameter.

Moreover, it provides such a laminate wherein such monofilaments areextruded. Additionally, it provides such a laminate wherein suchreinforcing elements include at least two unidirectional tapes, eachhaving extruded monofilaments therein, all of such monofilaments lyingin a predetermined direction within the tape, wherein such monofilamentshave diameters less than 20 microns and wherein spacing betweenindividual monofilaments within an adjoining strengthening group ofmonofilaments is within a gap distance in the range between non-abuttingmonofilaments up to nine times the monofilament major diameter. Also, itprovides such a laminate wherein each of such at least twounidirectional tapes includes larger areas without monofilaments thereinand wherein such larger areas comprise laminar overlays comprisingsmaller areas without monofilaments.

In addition, it provides such a laminate wherein such smaller areascomprise user-planned arrangements. And, it provides such a laminatefurther comprising a set of water-breathable elements comprising laminaroverlays of such smaller areas. Further, it provides such a laminatefurther comprising a set of other laminar overlays. Moreover, itprovides such a laminate wherein a first one of such at least twounidirectional tapes includes monofilaments lying in a differentpredetermined direction than a second one of such at least twounidirectional tapes.

Additionally, it provides such a laminate wherein a combination of thedifferent predetermined directions of such at least two unidirectionaltapes is user-selected to achieve laminate properties having planneddirectional rigidity/flexibility. Also, it provides such a laminatecomprising a three-dimensionally shaped, flexible composite part. Inaddition, it provides such a product comprising multiple laminatesegments attached along peripheral joints. And, it provides such aproduct comprising at least one laminate segment attached alongperipheral joints with at least one non-laminate segment. Further, itprovides such a product comprising multiple laminate segments attachedalong area joints.

Even further, it provides such a product comprising at least onelaminate segment attached along area joints with at least onenon-laminate segment. Moreover, it provides such a product comprising atleast one laminate segment attached along area joints with at least oneunitape segment. Additionally, it provides such a product comprising atleast one laminate segment attached along area joints with at least onemonofilament segment. Also, it provides such a product furthercomprising at least one rigid element.

In accordance with another preferred embodiment hereof, this inventionprovides a product wherein such at least one unidirectional tape isattached to such product. In accordance with a preferred embodimenthereof, the present system provides each and every novel feature,element, combination, step and/or method disclosed or suggested by thispatent application.

Brief Glossary of Terms and Definitions

-   Adhesive: A curable resin used to combine composite materials.-   Anisotropic: Not isotropic; having mechanical and or physical    properties which vary with direction at a point in the material.-   Aerial Weight: The weight of fiber per unit area, this is often    expressed as grams per square meter (g/m²).-   Autoclave: A closed vessel for producing an environment of fluid    pressure, with or without heat, to an enclosed object which is    undergoing a chemical reaction or other operation.-   B-stage: Generally defined herein as an intermediate stage in the    reaction of some thermosetting resins. Materials are sometimes pre    cure to this stage, called “prepregs”, to facilitate handling and    processing prior to final cure.-   C-stage: Final stage in the reaction of certain resins in which the    material is relatively insoluble and infusible.-   Cure: To change the properties of a polymer resin irreversibly by    chemical reaction. Cure may be accomplished by addition of curing    (cross-linking) agents, with or without catalyst, and with or    without heat.-   Decitex (DTEX): Unit of the linear density of a continuous filament    or yarn, equal to 1/10th of a tex or 9/10th of a denier-   Dyneema™ Ultra-high-molecular-weight polyethylene fiber by DSM-   Filament: The smallest unit of a fiber-containing material.    Filaments usually are of long length and small diameter.-   Polymer: An organic material composed of molecules of monomers    linked together.-   Prepreg: A ready-to-cure sheet or tape material. The resin is    partially cured to a B-stage and supplied to a layup step prior to    full cure.-   Tow: An untwisted bundle of continuous filaments.-   UHMWPE: Ultra-high-molecular-weight polyethylene. A type of    polyolefin made up of extremely long chains of polyethylene. Trade    names include Spectra® and Dyneema®-   Unitape Uni-Directional tape (UD tape)—flexible reinforced tapes    (also referred to as sheets) having uniformly-dense arrangements of    reinforcing fibers in parallel alignment and impregnated with an    adhesive resin. UD tape are typically B-staged and form the basic    unit of most CT composite fabrics.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1A is an illustration of S06 where A is the fiber, B is the matrixand C is the woven material, note there is no top or bottom coating; and

FIG. 1B is an illustration of S07 and S13 where A is the fiber and B isthe matrix material, C in this FIGURE preferably comprises a waterproofnon-breathable urethane film.

DETAILED DESCRIPTION

TABLE 1 Sample Delamination rank after ½ Sample hour wash/ weight LayerLayer Layer Layer Layer Additional Comments Number durabilitytranslucence (gsm) 1 2 3 4 5 comments white woven S06 3 4 64 releaseliner #538 WHC #538 release liner Non-waterproof inner layer no removed0° 2 90° removed breathable outer coatings after after and naturalprocess process color, 0/90 fibers, moderate air permeable no coatingone S07 5 4 92 W2-1.0 #5380°  #5380° release liner Waterproof side,coated on removed Non-breathable the other, 0/60 after fiber, naturalprocess color no coating one S13 4 4 90 W2-1.0 #1420° #14260° releaseliner Waterproof side, coated on removed Non-breathable the other, 0/60after fiber, grey process

Each of the materials of Table (1) preferably utilize Unitape layers. Apreferred Unitape layers is preferably manufactured by spreading fibersand coating them with an adhesive to form a substantially continuoussheet. The preferred Unitape layers are non-woven.

More specifically, each of the flexible sheet materials of Table (1)preferably utilizes Unitape layers (either applicant's #538 or #142Unitape). Preferably, these unitape “sheets” are cut to size and layedin multiple orientations to form a preferred two directional fiberreinforced sheet. Each of the materials of Table (1) preferably utilizeUnitape layers (either #538 or #142) with following preferredcharacteristics:

-   -   About 14 gsm of non-breathable CT71 adhesive in the unitape and        14 gsm of Dyneema SK75 1760Dtex fiber, which, when cross plied,        preferably creates a fiber matrix network that will bead water        and will be air permeable but will allow water to pass through        with significant atmospheric pressure.    -   Unitape #142 has a small amount of light grey tint in the CT71        adhesive that makes the resulting products have a light grey        color.    -   Unitape #538 is natural colored (translucent pale yellow) so the        resulting products are translucent pale yellow.

As illustrated in FIGS. 1A and 1B, laminate S06 has no film or membraneon either side of the laminate but has the woven material we have codedas WHC2 (Nylon 6 ripstop, 10d×10d+30d, 255×218, 26 g/sqm, C6:DWR)sandwiched between the unitape layers, the purpose of the woven is toadd rip-stop performance to the laminate and add structural stability tothe laminate. This material is a typical 0/90° orientation but has lowerthan normal modulus in the +/−45° directions because of the lack of filmor membrane Laminate S07 does not have a film or membrane on one sidebut has a non-breathable urethane membrane film W2−1.0 on the other sideso that it is waterproof-non breathable with fibers laid at about 0° and60° so the material (through the combination of the fiber angles andstretchable film) has low modulus in the 120° direction and moderatemodulus in the 30° direction Laminate S13 is same as S07 but is lightgrey because of the unitape used.

The “membrane-free” flexible composite generally exhibits greater“stretch”, or modulus attained, or rebound ability (of the materials inthe non-fiber reinforced directions), when compared to applicant'sprior-disclosed embodiments (see U.S. Pat. No. 5,470,632 to HeinerMeldner et al). Applicant's new disclosed embodiments are preferablydesigned to have a low modulus or rebound in the off axis directions.

It is noted that applicant's preferred adhesive coating (CT71) ispreferably a partially thermosetting polymer that has excellent adhesionto low surface energy fibers (and films, as applicable) and forms atoughened finished product once cured that is puncture resistant andresists UV degradation. Upon reading this specification, those withordinary skill in the art will now appreciate that, under appropriatecircumstances, considering such issues as design preference, intendeduse, cost, structural requirements, available materials, technologicaladvances, etc., other laminate versions, such as, for example, anon-breathable membrane applied on one or both sides of the layupassembly, which preferably could be replaced with breathable membranes.

In another preferred embodiment of the present invention, materials havean engineered stretch wherein the finished material stretch and reboundand design directions may be used in designed amounts. For example, aflexible composite with a high modulus from initial strain in the X-Yplain directions 0°/180°, 90°/270°, and 45°/225° but lower strengths,from initial strain, in all other x-y plane directions.

Preferably, the initial modulus of the material drops off as thedirection of stress moves farther and farther from a fiber reinforceddirection and increases as the load moves back towards a fiberreinforced direction. By knowing the material characteristics of eachcomponent ply and the interaction effects they have with each other amaterial can be manufactured with particular characteristics that may bedrastically different than the constituent components.

The following table discloses Unitape layers (applicant's #538 Unitape).Preferably, these unitape “sheets” are cut to size and layed in multipleorientations to form a preferred multi-directional fiber reinforcedsheet. Each of the materials of Table (2) preferably utilize Unitapelayers (either #538) in angular orientation (0-degrees; 45-degrees) withfollowing preferred characteristics, as shown:

Product Sample Aprox. name Number weight (gsm) Layer 1 Layer 2 Layer 3Layer 4 Layer 5 CT9BW6-2.0 (45) S40 215 W6-2.0 #538 0° #538 45° #538−45° W6-2.0 CT9BW2- S45 163 Tricot knit #538 0° #538 45° #538 −45°W2-1.0 1.0/TR1 (45) (any

Preferably, each of the materials above preferably utilize Unitapelayers. Preferred Unitape layers are preferably manufactured byspreading fibers and coating them with an adhesive to form asubstantially continuous sheet. The preferred Unitape layers are nonwoven.

More specifically, each of the flexible sheet materials of the aboveTable 2 preferably utilizes Unitape layers (applicant's #538 Unitape).Preferably, these unitape “sheets” are cut to size and laid in multipleorientations to form a preferred three directional fiber reinforcedsheet. Each of the materials of Table (1) preferably utilize Unitapelayers (#538) with the following preferred characteristics:

-   -   About 14 gsm of non-breathable CT71 adhesive in the unitape and        14 gsm of Dyneema SK75 1760Dtex fiber, which, when cross plied,        preferably creates a fiber matrix network that will bead water        and will be air permeable but will allow water to pass through        with significant atmospheric pressure.    -   Unitape #538 may include additives that cause it to become        colored to inventors desire    -   Unitape #538 is natural colored (translucent pale yellow) so the        resulting products are translucent pale yellow.

Additionally, as illustrated above, laminate S40 preferably has anon-breathable weldable urethane film W6−2.0 on both the bottom and topsurfaces and three layers of #538 unitape. This material is a 0/+45/−45′unitape orientation and has low modulus in 90° directions because of thelack of fiber in that direction.

Laminate S45 preferably has a tricot knit on one side for added abrasionresistance and a non-breathable urethane membrane film W6−2.0 on theother side so that the laminate is waterproof-non breathable with fiberslaid at about O″ +45°, and −45° so the material (through the combinationof the fiber angles and stretchable film and stretchable tricot) has lowmodulus in the 90′ direction.

Additional alternative surface coatings may include various types ofknits, wovens, non-wovens, meshes, breathable films (porous and nonporous), multilayered films, foams. Preferably, adding variousmaterials, as noted, into the stack of plies in configurations otherthan described for instance: having a woven material between layers ofunitape; having a film layer between unitape plies; having a wovenmaterial and a weldable film layer between two plies of unitape etc, maysuffice.

Further, other preferred alternative fiber angles could be used to drivehigh modulus in fiber reinforced directions and low modulus in non-fiberreinforced directions (assuming flexible matrix and other non-fibercomponents are also low-modulus).

Upon reading this specification, those with ordinary skill in the artwill now appreciate that, under appropriate circumstances, consideringsuch issues as design preference, user preferences, marketingpreferences, cost, structural requirements, available materials,technological advances, etc., other material arrangements such as, forexample, material could be cured inside or outside an autoclave, exactmaterial unitapes and other components may be changed to control themodulus of the material in off and on fiber axis directions, etc., maysuffice.

And, upon reading this specification, those with ordinary skill in theart will now appreciate that, under appropriate circumstances,considering such issues as design preference, user preferences,marketing preferences, cost, structural requirements, availablematerials, technological advances, etc., other adhesive arrangementssuch as, for example, removing current surface coatings and utilizingct71 to be both the adhesive and the coating, etc., may suffice.Alternately preferably, no adhesive may be needed if the fibers areweldable to themselves and/or the surface coatings.

Further, upon reading this specification, those with ordinary skill inthe art will now appreciate that, under appropriate circumstances,considering such issues as design preference, user preferences,marketing preferences, cost, structural requirements, availablematerials, technological advances, etc., other materials and layeringarrangements to improve performance and usability, such as thoseindicated below, may suffice:

-   -   i. Resin        -   1. toughening agents        -   2. breathable adhesive        -   3. non-breathable adhesive        -   4. FR additives        -   5. No-stink additives        -   6. Other resins            -   a. Water based            -   b. PU's    -   ii. thin films        -   1. breathable film        -   2. non breathable        -   3. directionally strong films    -   iii. texture could be added    -   iv. abrasion layers        -   1. woven nylon        -   2. woven polyester        -   3. non-wovens        -   4. super fabric    -   v. non-woven layers        -   1. on outer surface        -   2. between plies    -   vi. unitape fiber        -   1. fiber types            -   a. aramid            -   b. para aramid            -   c. Liquid Crystal Polymers            -   d. UHMEPE            -   e. Polyesters            -   f Polyamides (Nylons)            -   g. Polybenzimidazole        -   2. Resin content            -   a. Increased            -   b. Decreased        -   3. Amount of fiber            -   a. Increased            -   b. Decreased        -   4. Unitape Fiber hybrids            -   a. Intra laminar            -   b. Inter laminar    -   vii. Ply count can change    -   viii. Unitape per ply can change    -   ix. Unitape directions can change

And, upon reading this specification, those with ordinary skill in theart will now appreciate that, under appropriate circumstances,considering such issues as design preference, user preferences,marketing preferences, cost, structural requirements, availablematerials, technological advances, etc., other uses such as, forexample, medical bracing, safety devices (fall straps), etc., maysuffice.

Although applicant has described applicant's preferred embodiments ofthis invention, it will be understood that the broadest scope of thisinvention includes modifications such as diverse shapes, sizes, andmaterials. Such scope is limited only by the below claims as read inconnection with the above specification. Further, many other advantagesof applicant's invention will be apparent to those skilled in the artfrom the above descriptions and the below claims.

What is claimed is:
 1. A laminate comprising: reinforcing elementscomprising at least one unidirectional tape; and monofilaments disposedwithin said unidirectional tape, wherein all of said monofilaments aresituated in a predetermined direction within said tape; wherein saidmonofilaments have diameters less than 20 microns; and whereinindividual monofilaments abut adjacent monofilaments or wherein spacingbetween individual monofilaments within an adjoining strengthening groupof monofilaments is within a gap distance in the range betweennon-abutting monofilaments up to nine times the monofilament majordiameter.